Track system for supporting wall studs

ABSTRACT

An apparatus for supporting and retaining a plurality of parallel spaced apart wall studs comprises a longitudinally extending base having first and second side edges and first and second opposed sidewalls extending generally perpendicular to the base from the first and second side edges, wherein the base and sidewalls together define a trough for receiving and retaining an end portion of the plurality of wall studs. The apparatus further comprises a plurality of clips sized to fit within and extend transversely across the trough, each of the plurality of clips having first and second tabs extending from the base wherein the first and second tabs each define a slot with a corresponding of the first and second sidewalls sized to receive a portion of the wall studs therein.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/341,858 filed May 26, 2016 entitled Track System for SupportingWall Studs.

BACKGROUND OF THE INVENTION 1. Field of Invention

The present invention relates generally to construction and inparticular to a method and apparatus for supporting a plurality ofparallel spaced apart wall studs.

2. Description of Related Art

Metal wall studs are commonly used in the construction trade for framingwalls and other structures. The studs are installed at spaced intervalsto provide a framework for installation of drywall panels and the like.

Various track systems are known in the prior art for supporting wallstuds at the desired location. Such systems typically comprise a toptrack secured to the ceiling and a bottom track secured to the floor inalignment with the top track. Each wall stud is positioned between thetop and bottom tracks and secured in place with screws or crimping. Inthe case of “slip track” systems, the wall studs may be cut to a lengthless than the overall vertical distance between the top and bottomtracks. This permits some movement of the top track relative to thebottom track after installation of the wall studs. Slip track systemscan thus accommodate deflection in the ceiling position relative to thewall and floor, for example due to changes in applied loads ortemperature fluctuations. In some prior art systems an outer track and amovable inner track are provided to achieve the slip trackfunctionality.

In conventional wall construction systems each stud is secured to thetop and bottom tracks with fasteners, such as metal screws. Thistypically requires installers to use a ladder and a screw gun to securethe top end of each stud to the top track and building frame. The bottomend of each stud is secured to the bottom track in a similar manner. Insome cases, inexperienced tradesmen may install the studs at incorrecttrack locations, resulting in inconsistent spacing between the studs oroff-vertical positioning. In such cases it is time-consuming andlabour-intensive to remove the fasteners from the tracks and reinstallthe wall studs in the correct orientation.

Some fastener-less stud alignment systems are known in the prior artwhere wall studs are held in place with clips or tabs formed in thetracks rather than by separate fasteners. Such systems avoid the needfor screw guns or other tools for driving fasteners. However, in somecases the track clips are not designed to receive standard wall studsand custom studs must be used. In other cases, studs cannot be easilyextracted from the clips after installation, particularly in the case ofheavier gauge studs.

U.S. Pat. No. 6,647,691, Becker et al., exemplifies the prior art inthis field. Becker describes a track arrangement for supporting wallstuds where the studs are held in place in the tracks with opposedclips. Each clip consists of a portion of track sidewall bent inwardlyto form a cam surface and a stud ridge receiver. The studs may or maynot be bottomed-out in the tracks depending on whether or not the wallis load bearing.

One drawback of the Becker et al. track arrangement is that, onceinstalled, the wall studs cannot be easily decoupled from the tracks.Rather, significant force would be required to extract the stud sideflanges from the track clips. Also, the Becker et al. arrangementrequires that each stud be inserted within the top and bottom tracks inthe same orientation, i.e. with stud side flanges projecting in onedirection only. Furthermore, the Becker et al. system requires punchingthe tabs from the track itself which disadvantageously compromises thecontinuity of the track and may be prohibited by some building codes.

U.S. Pat. No. 8,615,959 B2, Ferguson et al. also describes a trackarrangement for supporting wall studs where the studs are held in placewith tabs and slots formed in the tracks by use of a metal press.Similar to Becker et al., a drawback of this arrangement is that in somejurisdictions building code specifies that cuts or notches through theflanges of the tracks are not permitted.

SUMMARY OF THE INVENTION

According to a first embodiment of the present invention there isdisclosed an apparatus for supporting and retaining a plurality ofparallel spaced apart wall studs. The apparatus comprises alongitudinally extending base having first and second side edges andfirst and second opposed sidewalls extending generally perpendicular tothe base from the first and second side edges, wherein the base andsidewalls together define a trough for receiving and retaining an endportion of the plurality of wall studs. The apparatus further comprisesa plurality of clips sized to fit within and extend transversely acrossthe trough, each of the plurality of clips having first and second tabsextending from the base wherein the first and second tabs each define aslot with a corresponding of the first and second sidewalls sized toreceive a portion of the wall studs therein.

The clip may include a bottom portion extending between the first andsecond tabs. The bottom portion of the clip may be substantially planar.The bottom portion of the clip may be secured to the base. The first andsecond tabs may extend substantially parallel to the first and secondside walls.

Each of the first and second tabs may include a bottom portion proximateto the base portion and a top portion distal from the base portion ofthe clip. The bottom and top portions may have a bend angletherebetween. The bottom portion may be angled towards the first orsecond side wall and wherein the top portion is angled away from thefirst or second side wall.

Each of the plurality of clips may be formed from a substantially planarunitary sheet of material. The plurality of clips may be spaced alongthe trough at regular intervals. The slots may be adapted to restrainhorizontal movement of the stud located therein in the engaged position.The slots may be adapted to permit vertical movement of the stud locatedtherein between engaged and disengaged positions by sliding the studvertically.

According to a first embodiment of the present invention there isdisclosed a kit for forming a wall comprising at least one top track, atleast one bottom track and a plurality of metal wall studs havingsidewalls sized to be received within the slots of the top and bottomtracks. Each of the top and bottom tracks comprises a longitudinallyextending base having first and second side edges and first and secondopposed sidewalls extending generally perpendicular to the base from thefirst and second side edges, wherein the base and sidewalls togetherdefine a trough for receiving and retaining an end portion of theplurality of wall studs. Each of the top and bottom tracks furthercomprises a plurality of clips sized to fit within and extendtransversely across the trough, each of the plurality of clips havingfirst and second tabs extending from the base wherein the first andsecond tabs each define a slot with a corresponding of the first andsecond sidewalls sized to receive a portion of the wall studs therein.The kit further comprises

The base of the top track may extend along a plane parallel to the baseof the bottom track at a distance greater than a length of the pluralityof metal studs to permit the relative sliding movement of the pluralityof metal studs. The trough of the top track may have a depth exceeding adepth of the trough of the bottom track. The tabs of the top track mayhave a length exceeding a length of the tabs of the bottom track todefine corresponding larger slots in the top track.

According to a first embodiment of the present invention there isdisclosed a method for forming a wall comprising securing a bottom trackto a floor surface and securing a top track to a ceiling surface. Eachof the bottom top tracks comprises a longitudinally extending basehaving first and second side edges and first and second opposedsidewalls extending generally perpendicular to the base from the firstand second side edges, wherein the base and sidewalls together define atrough for receiving and retaining an end portion of the plurality ofwall studs. Each of the bottom and top tracks further comprise aplurality of clips sized to fit within and extend transversely acrossthe trough, each of the plurality of clips having first and second tabsextending from the base wherein the first and second tabs each define aslot with a corresponding of the first and second sidewalls sized toreceive a portion of the wall studs therein. The method furthercomprises providing a plurality of metal wall studs, engaging a top endof each of the plurality of metal wall studs within the slots of the toptrack, rotating each of the plurality of metal studs into alignment withthe slots of the bottom track and vertically moving each of theplurality of metal studs into engagement with the bottom slots of thebottom track.

Other aspects and features of the present invention will become apparentto those ordinarily skilled in the art upon review of the followingdescription of specific embodiments of the invention in conjunction withthe accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate embodiments of the invention whereinsimilar characters of reference denote corresponding parts in each view,

FIG. 1 is a perspective view of an assembly for forming a wall accordingto a first embodiment of the present invention.

FIG. 2 is a perspective view of a top track of the assembly of FIG. 1.

FIG. 3 is a cross-sectional view of the top track of FIG. 2 as takenalong section lines 3-3.

FIG. 4 is a plan view of a cut sheet for forming a clip for use in thetop track of FIG. 2.

FIG. 5 is a front view of the bent top track clip of FIG. 4.

FIG. 6 is a perspective view of a bottom track of the assembly of FIG.1.

FIG. 7 is a cross-sectional view of the bottom track of FIG. 6 takenalong section 7-7.

FIG. 8 is a plan view of a cut sheet for forming a clip for use in thebottom track of FIG. 6.

FIG. 9 is a front view of the bent bottom track clip of FIG. 8.

FIG. 10 is a fragmented, perspective view of the track assembly showingsteps for releasably coupling a wall stud to the top and bottom tracks.

FIG. 11 is a detailed, cross-sectional view showing a lower end of awall stud disposed above a track slot.

FIG. 12 is a detailed, cross-sectional view showing a lower end of awall stud seated within a track slot.

DETAILED DESCRIPTION

Referring to FIG. 1, a track assembly 10 for supporting wall studs 9 isgenerally illustrated at 10. Track assembly 10 includes a top track 14attached to the ceiling framework of a building and a bottom track 40attached to the floor of a building. The top track 14 includes ahorizontal base 18 and a pair of opposed vertical sidewalls 20 extendinggenerally perpendicular to base 18. The bottom track 40 includes ahorizontal base 42 and a pair of opposed vertical sidewalls 44 extendinggenerally perpendicular to the base 42. Base 18 with sidewalls 20 andbase 42 with sidewalls 44 together define generally U-shaped top andbottom troughs 22 and 41. As described further below, each top andbottom trough 22 and 41 is sized to receive an end 6, 5 of a stud 9therein. The height of sidewall 20 and hence the depth of top trough 22may be larger in the top track 14 (FIGS. 2-3) than the height ofsidewall 44 and hence the depth of bottom trough 41 of the bottom track40 (FIGS. 6-7).

As shown best in FIG. 10, each stud 9 includes a base 8 and opposedflanges or sidewalls 7 extending in parallel planes perpendicular tobase 8. Studs 9 are conventional in structure and are typicallyconstructed of 12-25-gauge steel. Studs 9 can be cut to the desiredlength by any commonly known means or selected to have the desiredlength.

As shown in FIG. 2, a plurality of clips 30 are laterally attached tothe base 18 or sidewall 20 of the top track 14 at regular intervals.Slots 31, as shown in FIG. 3, between opposed sidewalls 20 and clips 30are preferably aligned. In one embodiment of the invention, each slot 31is defined between a clip 30 and an adjacent portion of sidewall 20.Each clip 30 includes a fixed base portion 32 attachable to base 18 anda free side tab 34 extending distal from base portion 32 (FIGS. 2-3). Asdescribed further below, in one embodiment of the invention each clip 30may consist of a bent metal piece attached to base 18 or sidewall 20.

Clips 30 are preferably attached to base 18 at regular, spaced-apartlongitudinal intervals, with clip spacing distance 24. For example, theclip spacing distance 24 between clips 30 may be selected to correspondto the desired wall stud spacing. At respective ends of top track 14,clips 30 are attached at half of the clip spacing distance 24 from theend, as indicated at half clip spacing distance 26. End clips placed athalf clip spacing distance 26 form a full clip spacing distance 24 whenend portions of two top tracks 14 are longitudinally aligned. Clips 30may be attached to base by any known method.

Referring to FIG. 4, clips 30 may be made from any gauge sheet metal orany other suitable material. The clip material is bent at fold line 36,forming a base portion 32, and a pair of side tabs 34. Base portion 32is sized to have a length between fold lines 36 less than the width oftop trough 22, to allow for a slot 31 between the side tabs 34 and thesidewall 20, as shown on FIG. 3. The width of base portion 32 may be ofany size to be received within the opening of the selected wall studs.Side tabs 34 may be bent along the fold line 36 to form the at tab angle35 equal to or greater than 90°. When tab angle 35 is greater than 90°,a portion of the side tabs 34 on clip 30 may touch the sidewalls 20 oftop track 14 proximate to the free end 37. In this case, additionalslight bends (for example 45°) of clip 30 may be optionally placed atfold line 38, to allow for a gap between the free end 37 of side tabs 34on clip 30 and sidewalls 20 of top track 14.

As shown in FIG. 6, a plurality of clips 50 are laterally attached tothe base 42 or sidewall 44 of the bottom track 40 at regular intervals.Slots 51, as shown in FIG. 7, between opposed sidewalls 44 and clips 50are preferably aligned. In one embodiment of the invention, each slot 51is defined between a clip 50 and an adjacent portion of sidewall 44.Each clip 50 includes a fixed base portion 52 attachable to base 42 anda free side tab 54 extending distal from base portion 52 (FIGS. 6-7). Asdescribed further below, in one embodiment of the invention each clip 50may consist of a bent metal piece attached to base 42 or sidewall 44.

Clips 50 are preferably attached to base 42 at regular, spaced-apartlongitudinal intervals, with clip spacing distance 46. For example, theclip spacing distance 46 between clips 50 may be selected to correspondto the desired wall stud spacing. At respective ends of bottom track 40,clips 50 are attached at half of the clip spacing distance 46 from theend, as indicated at half clip spacing distance 48. End clips placed athalf clip spacing distance 48 form a full clip spacing distance 46 whenend portions of two bottom tracks 40 are longitudinally aligned. Clips50 may be attached to base 42 or sidewall 44 by any known method.

Referring to FIG. 8, clips 50 may be made from any gauge sheet metal orany other suitable material. The clip material is bent at fold line 56,forming a base portion 52, and a pair of side tabs 54. Base portion 52is sized to have a length between fold lines 56 less than the width ofbottom trough 41, to allow for a slot 51 between the side tabs 54 andthe sidewall 44, as shown on FIG. 7. The width of base portion 52 may beof any size to be received within the opening of the selected wallstuds. Side tabs 54 may be bent along the fold lines 56 to form tabangle 55 equal to or greater than 90°. When tab angle 55 is greater than90°, a portion of the side tabs 54 on clip 50 may touch the sidewalls 44of bottom track 40 proximate to the free end 57. In this case,additional slight bends (for example 45°) of clip 50 may be optionallyplaced at fold line 58, to allow for a gap between the free end 37 ofside tabs 54 on clip 50 and sidewalls 44 of bottom track 40.

In one embodiment of the invention, each clip 30, 50 may be generallyrectangular in shape. As will be appreciated by a person skilled in theart, clips 30, 50 may be formed in other configurations to define slots31, 51 of other shapes and sizes. In the illustrated embodiment, thelength of side tab 34 of clips 30 may be longer in top track 14 than thelength of side tab 54 of clips 50 in bottom track 40. The differencebetween the length of the tabs permits the studs to be inserted into thelonger slot and thereafter displaced therein to permit insertion intothe shorter slot, as described in greater detail below.

In use, top track 14 is secured to a ceiling framework of a structureand bottom track 40 is secured to the floor of the structure (FIG. 1).Top and bottom tracks 14, 40 are preferably installed so that slots 31,51 formed between top and bottom tracks 14, 40 and clips 30, 50 arevertically aligned. End portions of some top and bottom tracks 14, 40may abut a wall or may be longitudinally aligned as described above todefine top and bottom troughs 22, 41 of any desired length.

Referring to FIGS. 10-12, standard studs 9 are cut to the desired lengthto extend between tracks 14, 40. Preferably studs 9 are cut to a lengthwhich is slightly less than the installed distance between bases 18, 42of aligned top and bottom tracks 14, 40. By way of non-limiting example,studs 9 may be cut to a length which is shorter than the distancebetween bases 18, 42 of top and bottom tracks 14, 40. As shown in FIG.10, stud 9 may be secured to track assembly 10 by first lifting stud 9upwards as shown generally in direction 100 inserting upper end 6 ofstud 9 into top trough 22 of top track 14 so that sidewalls 7 at upperend 6 are received into opposed slots 31. The opposite lower end 5 ofstud 9 is then pivoted, in general direction 102, into position (FIGS.10-11) and dropped, in general direction 104, into aligned slots 51 ofbottom track 40 (FIG. 12). Once installed as aforesaid, the lowermostedge of stud 9 is supported on the base 42 of bottom track 40 as shownin FIG. 12.

Since the length of stud 9 is slightly less than the distance betweenbases 18, 42 of top and bottom tracks 14, 40, some relative movement oftrack assembly 10 and studs 9 is permitted. Such a “slip track” systempermits the top track 14 to shift vertically relative to studs 9 andbottom track 40 if the ceiling height of the structure shifts ordeflects. As will be appreciated by a person skilled in the art, changesin the relative spacing between the ceiling and floor of a structurecausing deflection of top track 14 may result from loads applied to thestructure and/or temperature fluctuations causing expansion orcontraction of structural components.

One significant advantage of the applicant's track assembly 10 is thatstud 9 may be securely coupled to track assembly 10 without the use ofspecial tools or fasteners. That is, one upper end 6 of each stud 9 maybe coupled to top track 14 as described above (FIG. 10) by an installerstanding on the floor of the structure and extending stud 9 upwardlytoward the ceiling. Accordingly, ladders or additional braces orfasteners are not required. The opposite lower end 5 of each stud 9 mayalso be secured to bottom track 40 as described above without the use offasteners or special tools. Thus studs 9 may be easily installed at thecorrect locations and intervals and installation errors by unskilledtradesmen are avoided.

Another advantage of track assembly 10 is that stud 9 may be connectedto track assembly 10 in any desired orientation (i.e. with sidewalls 7of stud 9 extending either toward or away from an end wall of thestructure). This allows studs 9 to be placed in the optimum orientationto suit the particular requirements of the wall in question.

A further advantage of track assembly 10 is that one or more selectedstuds 9 may be easily removed from track assembly 10 without the use ofladders or other special tools or equipment by reversing theinstallation procedure illustrated in FIG. 10, (i.e. by lifting stud 9upwardly, pivoting one lower end 5 out of bottom track 40 and thenlowering stud 9 out of top track 14 to de-couple it from track assembly10). It is often convenient to remove a stud 9 from a track assembly 10after initial installation to make room for electrical panels, plumbingor other building materials installed by sub-trades as construction of astructure progresses.

An additional advantage of track assembly 10 in the presented embodimentis that there are no cuts or notches forming holes in the sidewalls 20,44 to diminish the strength of the top and bottom tracks 14, 40.

While specific embodiments of the invention have been described andillustrated, such embodiments should be considered illustrative of theinvention only and not as limiting the invention as construed inaccordance with the accompanying claims.

What is claimed is:
 1. An apparatus for supporting and retaining aplurality of parallel spaced apart wall studs comprising: alongitudinally extending base having first and second side edges andfirst and second opposed sidewalls extending generally perpendicular tosaid base from said first and second side edges, wherein said base andsidewalls together define a trough for receiving and retaining an endportion of said plurality of wall studs; a plurality of clips sized tofit within and extend transversely across said trough, each of saidplurality of clips having first and second tabs extending from saidbase, wherein said first and second tabs each define a slot with acorresponding of said first and second sidewalls sized to receive aportion of the wall studs therein.
 2. The apparatus of claim 1 whereinsaid clip includes a bottom portion extending between said first andsecond tabs.
 3. The apparatus of claim 2 wherein said bottom portion ofsaid clip is substantially planar.
 4. The apparatus of claim 2 whereinsaid bottom portion of said clip is secured to said base.
 5. Theapparatus of claim 1 wherein said first and second tabs extendssubstantially parallel to said first and second side walls.
 6. Theapparatus of claim 1 wherein each of said first and second tabs includea bottom portion proximate to said base portion and a top portion distalfrom said base portion of said clip.
 7. The apparatus of claim 6 whereinsaid bottom and top portions have a bend angle therebetween.
 8. Theapparatus of claim 7 wherein said bottom portion is angled towards saidfirst or second side wall and wherein said top portion is angled awayfrom said first or second side wall.
 9. The kit of claim 1 wherein eachof said plurality of clips is formed from a substantially planar unitarysheet of material.
 10. The kit of claim 1 wherein said plurality ofclips are spaced along said trough at regular intervals.
 11. The kit ofclaim 1 wherein said slots are adapted to restrain horizontal movementof the stud located therein in the engaged position.
 12. The kit ofclaim 1 wherein said slots are adapted to permit vertical movement ofthe stud located therein between engaged and disengaged positions bysliding the stud vertically.
 13. A kit for forming a wall comprising: atleast one top track formed in accordance with claim 1; at least onebottom track formed in accordance with claim 1; and a plurality of metalwall studs having sidewalls sized to be received within said slots ofsaid top and bottom tracks.
 14. The kit of claim 14 wherein said base ofsaid top track extends along a plane parallel to said base of saidbottom track at a distance greater than a length of said plurality ofmetal studs to permit the relative sliding movement of said plurality ofmetal studs.
 15. The kit of claim 13 wherein said trough of said toptrack has a depth exceeding a depth of said trough of said bottom track.16. The kit of claim 13 wherein said tabs of said top track have alength exceeding a length of said tabs of said bottom track to definecorresponding larger slots in said top track.
 17. A method for forming awall comprising: securing a bottom track to a floor surface; securing atop track to a ceiling surface, wherein each of said bottom top trackscomprises: a longitudinally extending base having first and second sideedges and first and second opposed sidewalls extending generallyperpendicular to said base from said first and second side edges,wherein said base and sidewalls together define a trough for receivingand retaining an end portion of said plurality of wall studs; aplurality of clips sized to fit within and extend transversely acrosssaid trough, each of said plurality of clips having first and secondtabs extending from said base, wherein said first and second tabs eachdefine a slot with a corresponding of said first and second sidewallssized to receive a portion of the wall studs therein. providing aplurality of metal wall studs engaging a top end of each of saidplurality of metal wall studs within said slots of said top track;rotating each of said plurality of metal studs into alignment with saidslots of said bottom track; and vertically moving each of said pluralityof metal studs into engagement with said bottom slots of said bottomtrack.